Installation tool for wire connectors

ABSTRACT

An installation tool for installing wire connectors used in forming an insulated splice between the stripped ends of insulated electrical wires. The tool includes an elongated, generally hollow body drive member adapted to rotatably retain two cylindrically-shaped wrench heads. The wrench heads are provided with a receptacle each of which is adapted to receive a different size wire connector therein. The body drive member includes an interiorly disposed one-way clutch which coacts with each of the wrench heads and couples rotational torque thereto applied to the body drive member. In addition, the wrench heads may be provided with apertures which function as gauges to guide in installer as to the amount of insulation to be removed or stripped from the ends of the wires before installing a wire connector thereon. The wrench heads are each further provided with a coaxially disposed aperture adapted to receive an auxiliary drive member. Alternatively, the body drive member may be provided with a coaxially disposed aperture adapted to receive the auxiliary drive member.

United States Patent 1 Mazzeo et al.

[ INSTALLATION TOOL FOR WIRE CONNECTORS [75] Inventors: Charles F. Mazzeo, Scotch Plains;

Anthony J. Santos, Edison, both of NJ.

[73} Assignee: Amerace Corporation, New York,

221 Filed: June 24,1974

211 Appl. No.: 482,239

[52] US. Cl. 29/203 H [51] Int. Cl. B25h 27/02; H05k 13/00 [58] Field of Search..... 29/203 H, 203 HT, 203 l-IC; 81/1 19 [56] References Cited UNITED STATES PATENTS 3,769,862 11/1973 Miller 81/119 X 3,787,948 1/l974 Runge 29/203 H Primary Examiner-Thomas H. Eager Attorney, Agent, or FirmS. Michael Bender; Martin Sachs June 10, 1975 [57] ABSTRACT An installation tool for installing wire connectors used in forming an insulated splice between the stripped ends of insulated electrical wires. The tool includes an elongated, generally hollow body drive member adapted to rotatably retain two cylindrically-shaped wrench heads. The wrench heads are provided with a receptacle each of which is adapted to receive a different size wire connector therein. The body drive member includes an interiorly disposed one-way clutch which coacts with each of the wrench heads and couples rotational torque thereto applied to the body drive member. In addition, the wrench heads may be provided with apertures which function as gauges to guide in installer as to the amount of insulation to be removed or stripped from the ends of the wires before installing a wire connector thereon. The wrench heads are each further provided with a coaxially disposed aperture adapted to receive an auxiliary drive member. Alternatively, the body drive member may be provided with a coaxially disposed aperture adapted to receive the auxiliary drive member.

11 Claims, 3 Drawing Figures 1 INSTALLATION TOOL FOR WIRE CONNECTORS BACKGROUND OF THE INVENTION The present invention relates to hand tools and, more particularly, to a hand operable installation tool for installing wire connectors or wire nuts as they are sometimes called.

In accordance with the electrical code requirements of many localities, wire connectors are required to be used whenever the stripped ends of insulated electrically conducting wires are connected or spliced together. Such connectors generally comprise a connecting element contained within an electrically insulating housing which latter includes a protective flange or skirt adapted to extend over the terminuses of the removed or stripped insulation of the wires to be connected by the connecting element. Many wire connectors presently in use include axially spaced grooves or outwardly extending turning arms spaced on opposite sides of the connector housing to aid an installer in applying rotational torque to the connector. Generally these connectors are rotated with the fingers onto the ends of the wires to be connected together. In building a new house or factory, it is often necessary for electricians to install large numbers of these connectors each day causing their fingers to become tender and sore.

Prior art hand tools which are designed to provide a mechanical advantage for the electrician when he in stalls the wire connectors are generally of the type wherein the handle is offset (axially displaced) from the wrench socket adapted to receive the wire connector, Such connectors require relatively large amounts of space for operation and frequently slip off the wire connector while being used because the pressure being applied to the wire connector simultaneously with the rotational torque is offset from the axis of the wires. An example of this type of installation tool may be found in U.S. Pat. No. 3,787,948 to Runge issued Jan. 29, I974 and U.S. Pat. No. 3,769,862 to Miller issued Nov. 6, 1973. Such hand tools designed to aid the electrician have generally proven to be ineffective since they cannot be used in confined areas and frequently their use increases the connector installation time as compared to the time required to install a connector when only the fingers are used.

The present invention overcomes the shortcomings of the prior art by providing a hand operable installation tool which furnishes torque amplification as compared to using fingers alone when installing the wire connectors. This additional torque may be applied in a plurality of positions, since the wrist or fingers need not be aligned with the arms or grooves provided on the surface of the connector, thus relieving the strain on the wrist and fingers of the installer.

Accordingly, an object of the present invention is to provide a hand tool for installing insulated wire connectors of various sizes.

Another object of the present invention is to provide a hand tool for facilitating the installation of insulated wire connectors in confined areas.

A further object of the present invention is to provide a hand tool which includes a one-way clutch (e.g., ratchet means) for facilitating the installation of insulated wire connectors but prevents the removal thereof.

A still further object of the present invention is to provide a hand tool for installing wire connectors which is relatively small in size and inexpensive to fabricate.

A yet further object of the present invention is to provide a hand tool for installing insulated wire connectors which provides a torque advantage when compared to using fingers alone thereby reducing the fatigue of an installer thereof.

In brief, the present invention comprises an elongated generally hollow body drive member provided with an internally extending annular flange at each end. A cylindrically-shaped wrench head is adapted to rotate within the hollow at each end of the tubular body drive member and be retained therein by the annular flange. The outer end of each wrench head is provided with a receptacle complementary in shape to the insulated housing of a wire connector for receiving the latter therein. A one-way clutch engageable between each of the wrench heads and the drive member, is also provided. The one-way clutch is adapted to transmit torque applied to the body member to the wrench heads for causing the wrench heads to rotate about the longitudinal axis of the body member in only one direction.

Other objects and features of the present invention will become apparent from a study of the following detailed description of the invention made with reference to the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view ofa hand operable installation tool for wire connectors according to principles of the present invention, shown in cooperative relation with a wire connector and an auxiliary drive member;

FIG. 2 is an exploded perspective view, partially bro ken away, of the installation tool shown in FIG. I; and

FIG. 3 is a cross-sectional view of the installation tool shown in FIG. 2 fully assembled, taken along line 33 of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawing, and initially to FIG. I, there is shown a pictorial representation of the installa tion tool of the present invention generally designated by reference numeral 10, an auxiliary drive member 12, and a wire connector 14. The structural details of the wire connector 14 are considered outside the scope of the present invention. Accordingly, for a more complete understanding of same reference may be had to U.S. Pat. No. 3,308,229 to Burniston issued on Mar. 7, 1967 which fully discloses a typical wire connector with which the installation tool of the present invention may be employed. The wire connector 14 is typically provided with outwardly extending turning arms 16 spaced on opposite sides of the connector housing 18 to aid an installer in rotating the connector onto the ends of a pair of stripped wires to be connected together. In addition, a plurality of grooves 20 may also be provided on the connector housing to aid the installer in gripping and rotating the housing 18 with the fingers of the hand, although the function of such grooves is obviated by the present invention as will be made apparent below.

The auxiliary drive member 12 conventionally includes a cylindrically-shaped plastic handle 22 which is provided with grooves 24 about its periphery to aid an installer in transmitting rotational torque to same. The

handle 22 is also provided with a cylindrical, axially extending shaft 26 which is provided with a flattened rect angular shaped free end portion 27 of standard dimensions, e.g., A inch square. Included in the end portion 27 is a conventional friction or tension ball 29 which is adapted to retain the end portion of the auxiliary drive member in an aperture located within the hollow body member 28 as will be explained hereinafter.

The installation tool is shown in an exploded per spective view in FIG, 2, with its elongated tubularshaped body drive member 28 broken away to disclose two interior, axially spaced sets of parallel, oppositely facing, non-opposing, ratchet teeth 30 and 32 formed in the generally solid central portion 31 thereof and dis posed in a substantially coaxial manner with respect to the longitudinal axis of the body member 28. The term non-opposing" as used herein means that the drive sense of the teeth in ratchet set is the same as that corresponding to the teeth in ratchet set 32.

An enlarged cross-sectional view of the body drive member 28 and wrench heads 46 and 48 is shown in FIG. 3 with the two axially spaced, non-opposing ratchets 30 and 32 more clearly visible therein. In this regard, it will be noted that due to the inclined surface 34 and 36 on each of the ratchet teeth 30 and 32, respectively, they can only impart torque in one direction of rotation of the body drive member 28 with respect to the mating or cooperating ratchet teeth 42, 44 located on the inner ends of the wrench heads 46, 48 as will be more apparent hereinafter. Thus, broadly speaking, each set of cooperating ratchet teeth 30, 42 and 32, 44 functions as a one-way clutch.

The outer surface of body drive member 28 may be provided with knurling or grooves to increase its surface friction so as to make it easier for an installer to rotate the body drive member when the latter is torqued by hand. Preferably. a portion 41 of the periphery of the body drive member 28 is left clear to receive indicia indicating the size or type of wire connector the wrench head captive therein is adapted to re ceive, or the indicia or trademark of the manufacturer of the installation tool 10.

As shown in FIGS. 2 and 3, and as mentioned hereinbefore, ratchet teeth 42 and 44 are provided on the inner ends of the cylindrically-shaped wrench heads 46 and 48 whereas receptacles 60 and 62 are provided on the outer ends of the wrench heads 46 and 48, respectively. The wrench heads are adapted to be rotatably retained within the hollow portions 50 and 52, respectively, of body drive member 28 by the internally extending annular flange 54 and 56, respectively, provided at each end of the body drive member 28. Also provided in the wrench heads 46 and 48 are coaxial, rectangular-shaped apertures 72 and 74, respectively, the purpose of which will be explained in more detail below. When the wrench head 46 is in its engaged position the ratchet teeth 42 provided on its inner end engages the corresponding adjacent ratchet teeth 30 of the body drive member 28 and thus, in its engaged position is able to receive torque imparted to it from the rotation of the body drive member 28 in the direction of the arrows 58 as shown in FIGS. 1 and 2. The wrench head 46 thus may impart the torque to the wire connector 14 received within receptacle 60 therein, as shown in FIG. 1.

It will be observed that the wrench heads 46 and 48 are essentially identical except for the size and shape of the receptacles 60 and 62, and the wrench heads 46 and 48 as well as body drive member 28 preferably are molded from a suitable plastic material such as nylon, for example. The receptacles 60 and 62 provided in wrench heads 46 and 48 may be made identical and may be adapted to receive the same size and type of wire connectors, or they may be made to accept different sizes of the same type of wire connector, or any combination desired by the manufacturer thereof. Suffice it to say, the receptacles 60 and 62 are shaped complementary to the shape of the wire connectors desired to be installed and may be adapted to receive wire connectors which are provided either with turning arms, grooves, or other external features. The type of connector for which the installation tool 10 may be used thus depends upon the wrench heads that are inserted in the hollow portions 50 and 52 of the body drive member 28 during manufacture of the installation tool 10, since the wrench heads 46 and 48 are designed to be non-removable once they are installed. That is, the wrench heads 44 and 48 are adapted to be inserted into the hollow portions 50 and 52 of the body drive member 28 during manufacture of tool 10 preferably after the plastic body drive member has completely cured. The flange portions 54 and 56 of the body drive member 28 accordingly are adapted to expand slightly to accept the wrench heads into their respective hollow portions and then return to their normal retaining positions.

A series of blind apertures 64, 66, 68 and 70 having differing diameters and depths may also be included in the wrench heads 46 and 48 in the outer ends thereof. Apertures 64, 66, 68 and 70 are positioned about the periphery of their respective wrench heads and function as length gauges for different wire sizes to indicate to the installer the amount of insulation to be removed from the end of a wire in order to make a satisfactory splice or connection. A wire is inserted into one of the apertures 64-70 depending upon its size (diameter) after being stripped by an insulation cutting tool, e.g., knife, cutting pliers, etc. The bared portion of each wire is trimmed so that the terminus of the insulation is made flush with the outer surface of the wrench head with the stripped portion of the wire fully extending into the aperture.

It will be appreciated that torque may be transmitted to the body drive member 28 for purposes of installing wire connectors either by hand or by means of the auxiliary drive member 12. For the latter purpose, and as mentioned above, coaxial, rectangular shaped throughapertures 72, 74 may be provided in the wrench heads 46, 48 with the apertures 72, 74 communicating with the central aperture 33 provided in the generally solid central portion 31 of the body drive member 28 (see FIG. 3). Ledges 37, 39 are provided inwardly of the wrench heads adjacent the periphery of apertures 72, 74, respectively, for coacting with the shoulder 35 provided on the shaft portion 26 (FIG. 1) of the auxiliary drive member 12 to limit penetration of the shaft portion within each wrench head. The free end portion 27 of the auxiliary drive member may in some cases, depending upon the size of connector with which each wrench head is used, extend into the aperture 33 in the solid central portion of the body drive member.

Alternatively, the generally solid central portion 31 of body drive member 28 may be provided with a rectangular shaped, co-axial through-aperture 33 sized to receive and coact with the end portion of the auxiliary drive member 12 in which case the apertures 72, 74 in the respective wrench heads 46, 48 will be sized large enough to receive shaft 26 therethrough. With the latter arrangement, the shoulder 35 provided on the shaft portion 26 will abut against the periphery adjacent the aperture 33 to limit the further penetration of the shaft portion 26 into the aperture 33.

In operation, the installation tool 10 is used to install a wire connector 14 on a pair of stripped insulated wires by first placing the wire connector into one of the receptacles 60 or 62 of the wrench head 46 or 48 depending upon the size of the wire connector. Pressure is then applied to the body drive member 28 in the direction of the wire connector (i.e., along the longitudinal axis of member 28) at the same time rotational torque (twisting) is applied thereto, thus causing the ratchet teeth on the body drive member to engage the corresponding ratchet teeth provided on the wrench head 46 or 48, thereby imparting the rotational torque applied to the body member 28 to the wire connector 14, which is seated within the receptacle 60 or 62 of the wrench head 46 or 48. The rotational torque causes the wire connector to rotate relative to the wires being connected and be installed thereon in a conventional manner. If the pressure is released or the body drive member rotated in a counter-clockwise direction (opposite to that indicated by arrows 58) rotational torque applied to the body drive member will not be applied to the wire connector, via the wrench head, since there would be slippage between the ratchet teeth on the body drive member and the ratchet teeth on the engaged wrench head. Hence, the installation tool 10 may be employed to install the electrical connector, but cannot be used to remove same once it has been installed.

The auxiliary drive member 12 may be used particularly in confined areas by inserting shaft 26 thereof through the aperture 60, 62 and into the coaxial, rectangular-shaped aperture 72, 74 of the wrench head not being used to install a wire connector, until the end portion 27 seats within aperture 72 or 74. The ledge portion 37 or 39 prohibits the shaft 26 from completely entering the aperture, since it coacts with shoulder 35 thereof; and friction ball 29 tends to hold the shaft 26 within the aperture. Torque will thus be coupled from the auxiliary drive member 12, via the unused wrench head to the central portion 31 of the body member 28, to the installing wrench head, to the wire connector.

Alternatively, the auxiliary drive member 12 may be used by inserting shaft 26 thereof through either receptacle 60 or 62 and clearance aperture 72 or 74 (the wrench head not being used to install a wire connector) until the end portion 27 seats within the coaxial rectangular-shaped aperture 33 provided in the generally solid portion 31 of body drive member 28. The shoulder 35 prohibits the shaft 26 from completely entering opening 33 and the friction ball 29 holds the shaft 26 therein.

From the foregoing, it will be appreciated that the present invention discloses a rugged, simple, and relatively inexpensive hand operable tool for facilitating the installation of wire connectors. Although a preferred embodiment has been disclosed as required by statute, it is anticipated that many modifications thereto may be made by those ordinarily skilled in art.

Accordingly, the present invention should be limited only by the spirit and scope of the present claims.

Having thus set forth the nature of the invention, what is claimed is:

1. A hand operable installation tool comprising a. a substantially hollow elongated body member,

said body member being provided with an internally extending annular flange at each end;

b. two cylindrically-shaped wrench heads, one of said wrench heads being adapted to rotate within the hollow at each end of said body member and being adapted to be retained therein by said annular flanges, said wrench heads being provided with a receptacle on the outer end thereof complementary in shape to said wire connector for receiving the latter therein; and

c. one-way clutch means engageable between each of said wrench heads and said body member, said one-way clutch means being adapted to transmit torque applied to said body member to said wrench heads for causing said wrench heads to rotate unidirectionally about the longitudinal axis of said body member.

2. A hand operable installation tool according to claim 1 wherein said body member includes a substantially solid central section, said central section being provided with a portion of said one-way clutch means and said wrench heads include a coacting portion of said one-way clutch means on the inner end thereof.

3. A hand operable installation tool according to claim 2 wherein said one-way clutch means comprises coacting ratchet teeth disposed on the inner end of said wrench heads, said ratchet teeth being adapted to coact with a corresponding set of ratchet teeth interiorily disposed within said body member on said central section thereof.

4. An installation tool according to claim 1 wherein said elongated body member comprises a unitary structure.

5. An installation tool according to claim 1 wherein said body member is comprised of a plastic material.

6. An installation tool according to claim 1 wherein said wrench heads are comprised of a plastic material.

7. An installation tool according to claim 1 wherein said body member is provided with a coaxially disposed aperture adapted to receive an auxiliary drive member.

8. An installation tool according to claim I wherein said wrench heads are provided with a coaxially disposed aperture adapted to receive an auxiliary drive member.

9. An installation tool according to claim 1 wherein each said wrench head is provided with a plurality of apertures of different depths on said outer end, said apertures being spaced proximate the periphery thereof and being adapted to function as length gauges.

10. An installation tool according to claim 1 wherein each said wrench head receptacle is adapted to receive a different size wire connector.

11. An installation tool for wire connectors comprising:

a. a tubular-shaped body drive member, said body drive member being a unitary structure having an internally extending annular flange at each end and two interior axially spaced sets of parallel oppositely facing non-opposing ratchet teeth provided in a substantially solid central portion thereof; and

7 8 b. two cylindrically-shaped wrench heads, one of said to coact with a corresponding set of said body drive wrench heads being adapted to rota fi Wllhm the member ratchet teeth for receiving drive torque in hollow at each end of said tubular body drive member and adapted to be retained therein by said annular flanges, Said wrench heads being provided end thereof adapted to receive a wlre connector. with ratchet teeth on the inner end thereof adapted only one direction and a receptacle in the outer 

1. A hand operable installation tool comprising a. a substantially hollow elongated body member, said body member being provided with an internally extending annular flange at each end; b. two cylindrically-shaped wrench heads, one of said wrench heads being adapted to rotate within the hollow at each end of said body member and being adapted to be retained therein by said annular flanges, said wrench heads being provided with a receptacle on the outer end thereof complementary in shape to said wire connector for receiving the latter therein; and c. one-way clutch means engageable between each of said wrench heads and said body member, said one-way clutch means being adapted to transmit torque applied to said body member to said wrench heads for causing said wrench heads to rotate unidirectionally about the longitudinal axis of said body member.
 2. A hand operable installation tool according to claim 1 wherein said body member includes a substantially solid central section, said central section being provided with a portion of said one-way clutch means and said wrench heads include a coacting portion of said one-way clutch means on the inner end thEreof.
 3. A hand operable installation tool according to claim 2 wherein said one-way clutch means comprises coacting ratchet teeth disposed on the inner end of said wrench heads, said ratchet teeth being adapted to coact with a corresponding set of ratchet teeth interiorily disposed within said body member on said central section thereof.
 4. An installation tool according to claim 1 wherein said elongated body member comprises a unitary structure.
 5. An installation tool according to claim 1 wherein said body member is comprised of a plastic material.
 6. An installation tool according to claim 1 wherein said wrench heads are comprised of a plastic material.
 7. An installation tool according to claim 1 wherein said body member is provided with a coaxially disposed aperture adapted to receive an auxiliary drive member.
 8. An installation tool according to claim 1 wherein said wrench heads are provided with a coaxially disposed aperture adapted to receive an auxiliary drive member.
 9. An installation tool according to claim 1 wherein each said wrench head is provided with a plurality of apertures of different depths on said outer end, said apertures being spaced proximate the periphery thereof and being adapted to function as length gauges.
 10. An installation tool according to claim 1 wherein each said wrench head receptacle is adapted to receive a different size wire connector.
 11. An installation tool for wire connectors comprising: a. a tubular-shaped body drive member, said body drive member being a unitary structure having an internally extending annular flange at each end and two interior axially spaced sets of parallel oppositely facing non-opposing ratchet teeth provided in a substantially solid central portion thereof; and b. two cylindrically-shaped wrench heads, one of said wrench heads being adapted to rotate within the hollow at each end of said tubular body drive member and adapted to be retained therein by said annular flanges, said wrench heads being provided with ratchet teeth on the inner end thereof adapted to coact with a corresponding set of said body drive member ratchet teeth for receiving drive torque in only one direction and a receptacle in the outer end thereof adapted to receive a wire connector. 